"A ROLL OVER PROTECTION STRUCTURE"

FIELD OF THE INVENTION

This invention relates to a rollover protection structure and in particular a rollover protection structure for vehicles which may be used for vehicles including vehicles such as four wheel drive vehicles and the like.

BACKGROUND TO THE INVENTION

The modern motor vehicle includes many safety features in its structural design for protection of the vehicle's occupants in the event of an accident. Such features may include a strengthened chassis, strengthened door pillars, strengthened roof pillars and crumple zones. Despite many of these safety features, one of the most susceptible areas of the vehicle still remains the roof in roll over accidents.

For vehicles used in high risk industries, such as vehicles used in the mining industry, an after market roll cage may be fitted by licensed operators to protect the occupants in case of a vehicle roll over. The roll cage is typically fitted internally or externally to the vehicle using tubular steel. The problem with using tubular steel is that it adds a significant amount of weight to the vehicle and adversely affects the vehicle's centre of gravity. Additional problems associated with internally fitted roll cages is that they intrude into the inner space of the vehicle and occupants risk injury through contact with the roll cage in an accident. Furthermore, the roll cage may obstruct air bags and/or prevent their deployment. Normally, internally fitted roll cages are mounted against a skin of the vehicle. However in order to allow airbags to deploy, the roll cage is mounted away from the skin of the vehicle. This means that there is less space inside the vehicle and occupants may get trapped between the skin of the vehicle and the roll cage in an accident. An additional problem associated with external roll cages is that they interfere with the crumple zones incorporated into the vehicle.

US Patent Publication No US 2010/0045074 to Friedmann attempts to overcome the problems associated with the prior art roll cages described above. Friedmann discloses a vehicle rollover protection system mounted to a roof of a vehicle. The system comprises two longitudinal members that extend along the length of opposing sides of the roof of the vehicle. Transverse members extend between the longitudinal members at a front, a middle and a back of the vehicle in order to support an arc extending between the longitudinal members. Struts are connected between the arc and the transverse members to provide additional strength. The arc is positioned towards a front of the vehicle and/or towards a back of the vehicle. The arc is spaced from the centre of mass of the vehicle to cause the vehicle to continue to roll back onto its wheels. However as the structure is typically made from steel, it adds a significant amount of weight to the vehicle and adversely affects the vehicle's centre of gravity as described above. In addition, causing the vehicle to continue to roll may cause further injury to occupants and may move the vehicle to a more vulnerable location, for example, cause the vehicle to roll over an embankment. Furthermore, the aerodynamics of the vehicle are compromised. OBJECT OF THE INVENTION

It is an object of the invention to overcome or alleviate one or more of the above disadvantages and/or to provide the consumer with a useful or commercial choice.

SUMMARY OF THE INVENTION

In one form, although it need not be the only or indeed the broadest form, the invention resides in a roll over protection structure for mounting to a vehicle including: a base adapted to reduce an effect of external impact forces, at least in part, by:

1) distributing said external impact forces across structural pillars of the vehicle; and

2) absorbing the external impact forces.

In another form, the invention resides in a roll over protection structure for mounting to a vehicle including: a base, the base including: two or more longitudinal members for mounting to each side of a roof of a vehicle; and two or more transverse members extending between the longitudinal members, wherein an intersection between a transverse member and a longitudinal member is substantially adjacent one or more structural pillars of the vehicle. Preferably, the base is of unitary construction.

Preferably, the base is made of a composite material. Alternatively, the base is made of a pressed metal material.

Preferably, each transverse member extends substantially perpendicularly between each longitudinal member.

At least one of the transverse members may extend diagonally between each longitudinal member.

Preferably, the structural pillars of the vehicle include any one or more of an A-pillar, a B-pillar, a C-pillar and/or a D-pillar.

Optionally, the body includes pillar members that extend from an end of the longitudinal members and/or the transverse members along at least one structural pillar of the vehicle.

The base may be mounted to the roof of the vehicle using an adhesive.

Preferably, the transverse members are spaced apart from the roof of the vehicle.

Optionally, the transverse members are mounted to the roof of the vehicle and follow a contour of the vehicle.

Preferably, a first transverse member forms an arc and is connected between the longitudinal members at a point that corresponds to the A-pillars of the vehicle when mounted to the vehicle. A mid-point of the first transverse member may intersect a mid point of a second transverse member connected between the longitudinal members adjacent a respective B-Pillar.

In yet another form, the invention resides in a roll over protection structure for mounting to a vehicle including: a base, wherein a bottom surface of the base is moulded to complement at least part of a roof of the vehicle; and two or more transverse members formed on a top surface of the base; wherein each of the transverse members extend between opposing sides of the base; and opposing ends of each of the transverse members are adjacent structural pillars of the vehicle.

Preferably, the transverse members and the base are integrally formed.

Preferably a transverse member extends perpendicularly between opposing sides of the base.

Preferably, a transverse member extends diagonally between opposing sides of the base. Preferably, the transverse members and the base are made from a composite material. Alternatively, transverse members and the base are made of a pressed metal material. The transverse members and the base may be hollow or solid. Optionally, the transverse members and the base are filled with a structural foam. Optionally, the base and the transverse members include reinforcing members.

Suitably, longitudinal members extend between the transverse members. Optionally, the longitudinal members are integrally formed with the base and the transverse members.

Optionally, a cut-out is formed in the base towards a front of the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

To assist in understanding the invention and to enable a person skilled in the art to put the invention into practical effect, preferred embodiments of the invention will be described by way of example only with reference to the accompanying drawings, in which:

FIG 1 shows a front perspective view of a roll over protection structure, according to a first embodiment of the present invention, mounted to a vehicle;

FIG 2 shows a rear perspective view of the roll over protection structure of FIG 1 mounted to a vehicle;

FIG 3 shows a side view of the roll over protection structure of FIG 1 mounted to a;

FIG 4 shows a top view of the roll over protection structure of FIG 1 mounted to a vehicle; FIG 5 shows a front view of the roll over protection structure of FIG 1 mounted to a vehicle;

FIG 6 shows a rear view of the roll over protection structure of FIG 1 mounted to a vehicle; FIG 7 shows a front perspective view of a roll over protection system according to a second embodiment of the present invention;

FIG 8 shows a rear perspective view of the roll over protection structure of FIG 7;

FIG 9 shows a cross-section of a front perspective view of the roll over protection system of FIGS 7 and 8;

FIG 10 shows a front perspective view of the roll over protection structure of FIGS 7 and 8 mounted to a vehicle;

FIG 11 shows a rear perspective view of the roll over protection structure of FIGS 7 and 8 mounted to a vehicle; FIG 12 shows a front perspective view of a roll over protection structure, according to a third embodiment of the present invention, mounted to a vehicle; and

FIG 13 shows a see through view of the roll over protection structure of FIG 12. DETAILED DESCRIPTION OF THE INVENTION

In this specification, adjectives such as first and second, left and right, and the like may be used solely to distinguish one element or action from 15

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another element or action without necessarily requiring or implying any such actual relationship or order. Words such as "comprises" or "includes" are intended to define a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed, including elements that are inherent to such a process, method, article, or apparatus.

FIGs 1-6 show a Roll Over Protection Structure (ROPS) 10 fitted to a vehicle 20, according to a first embodiment of the present invention. The vehicle 20 in the present embodiment is a 5-door, 4 wheel drive vehicle and includes structural pillars 22A, 22B, 22C, 22D. The structural pillars 22A, 22B, 22C, 22D include A-pillars 22A, B-pillars 22B, C-pillars 22C and D- pillars 22D as is known in the art. However it should be appreciated that the structure 10 may be adapted to be fitted to any suitable vehicle, for example a sedan, a hatchback, a station wagon, a coupe or a van.

The structure 10 is of unitary construction and is made of a lightweight composite material such as carbon-fibre reinforced plastics or fibre glass and may be a hollow or a solid construction. However it should be appreciated that any composite materials that are lightweight may be used. Additionally, the composite material may also include reinforcing members, such as aluminium rods or metallic fibres. In the case of a hollow structure 10, the structure 10 may be made from a lightweight sheet metal such as pressed steel or aluminium and welded or riveted together. Furthermore, a hollow structure 10 may include a skin filled with a structural foam material. 11 001215

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The structure 10 includes a base formed from longitudinal members 12A, 12B, transverse members 14A, 14B, 14C, 14D extending between the longitudinal members 12A, 12B, and pillar members 16A, 16B, 16C, 16D.

As shown in FIG 1 , each transverse member 14A, 14B, 14C, 14D extends substantially perpendicularly between the longitudinal members 12A, 12B. That is to say that opposing ends of each transverse member 14A, 14B, 14C, 14D intersect the longitudinal members 12A, 12B at a point adjacent a same type of structural pillar 22A, 22B on either side of the vehicle 20. In particular, first transverse member 14A intersects the longitudinal member 12A, 12B adjacent the A-pillars 22A of the vehicle 20, second transverse member 14B intersects the longitudinal members 12A, 12B adjacent the B-pillars 22B of the vehicle 20, third transverse member 14C intersects the longitudinal members 12A, 12B adjacent the C-pillars 22A of the vehicle 20, and fourth transverse member 14D intersects the longitudinal members 12A, 12B adjacent the D-pillars 22D of the vehicle 20.

Alternatively, but not shown, each transverse member may extend diagonally between the longitudinal members. That is to say that opposing ends of each transverse member intersect the longitudinal members at a point adjacent a different type of structural pillar on either side of the vehicle. A first transverse member 14A forms an arc between a first longitudinal member 12A and a second longitudinal member 12B. The first transverse member 14A intersects the longitudinal members 12A, 12B adjacent the A-pillars 22A, 22B of the vehicle 20. A mid-point of the arc of the first transverse member 14A intersects a mid-point of the second transverse member 14B that extends between the first and second longitudinal members 2A, 2B. It should be appreciated however that the first transverse member 14A may not intersect with the second transverse member 14B and may connect directly between the longitudinal members 12A, 12B. Furthermore, the first transverse member may not form an arc and may be a straight section.

The second transverse member 14B intersects the longitudinal members 12A, 12B adjacent the B-pillars 22B of the vehicle 20. A third transverse member 14C extends between the longitudinal members 12A, 2B and intersects the longitudinal members 12A, 12B adjacent the C-pillars 22C of the vehicle 20. A fourth transverse member 14D intersects the longitudinal members 12A, 12B adjacent the D-pillars 22D of the vehicle 20. When fitted to the vehicle 20, the transverse members 14A, 14B, 14C, 14D are spaced apart from a roof of the vehicle 20 and prevents moisture from being trapped between the transverse members 14A, 14B, 14C, 14D and the roof which may lead the roof rusting. However, it should be appreciated that the transverse members 14A, 14B, 14C, 14D may be directly bonded to the roof of the vehicle and follow a contour of the roof of the vehicle 20.

The pillar members 16A, 16B, 16C, 16D extend from opposing ends of the longitudinal members 12A, 12B and partially along outermost structural pillars, namely the A-pillars 22A and the D-pillars 22D of the vehicle 20. First and second pillar members 16A, 16B are located towards a front 20A of the vehicle 20, and third and fourth pillar members 16C, 16D located towards a rear 20B of the vehicle 20. The first and second pillar members 16A, 16B extend from a proximal end of a respective longitudinal member 12A, 12B and partially along the A- pillars 22A of the vehicle 20. The third and fourth pillar members 16C, 16D extend from a distal end of a respective longitudinal member 12A, 12B and partially along a respective D-pillar 22D of the vehicle 20. ft should be appreciated that the structure 10 may be adapted for use on vehicles that have two or three structural pillars or more than four structural pillars. In this case the pillar members 16 extend along forward most structural pillars and rearmost structural pillars. Furthermore, for vehicles with four structural pillars (A, B, C and D structural pillars), the pillar members 16 may also extend along the B and C pillars 22B, 22C where the design of the vehicle allows.

FIG 6 shows an accessory 50 in the form of high mounted lights 52 integrated into the structure 10. Furthermore, the structure 10 may provide mounting points for other accessories such as flashing lights and antennas.

FIGS 7 and 8 show diagrams of front and rear perspective views respectively of a roll over protection structure 30 according to a second embodiment of the invention. FIG 9 shows a diagram of a cross-sectional front perspective view of the roll over protection structure 30 of FIGS 7 and 8 and FIGS 10 and 11 show the roll over protection system 30 of FIGS 7 and 8 mounted to a roof of a vehicle 40. The vehicle 40 includes structural pillars including A-pillars 42A, B-pillars 42B, C-pillars 42C and D-pillars 42D.

The structure 30 includes a base 31 , longitudinal members 32A, 32B, and transverse members 34B, 34C, 34D. The base 31 and the transverse members 34B, 34C, 340 are integrally formed and are made from a composite material or a pressed metal such as those previously described.

Referring to FIGS 7 to 11 , a bottom surface of the base 31 is moulded to complement a roof 44 of the vehicle 40. The base 31 covers a length of the roof of the vehicle 40 except for a cut-out 33 that corresponds with a sunroof of the vehicle 40. However it should be appreciated that the base 31 may not include a cut-out 33 in the case where the vehicle does not include a sunroof.

Referring to FIG 9, the base 31 and the transverse members 34 are hollow and filled with a structural expandable foam 31 C such as polyurethane however it should be appreciated that other suitable materials may be used. Furthermore, it should be appreciated that the base 31 and the transverse members 34 may not include a filling. Additionally, the base 31 and the transverse members 34 may be solid and include reinforcing members such as metal bars and/or fibres.

The transverse members 34B, 34C, 34D are integrally formed on a top surface of the base 31 and extend between opposing sides 31 A, 31 B of the base 31. The transverse members 34B, 34C, 34D protrude above a generally flat top surface of the base 31. Although a first transverse member is not shown in the second embodiment, it should be appreciated that the structure 30 may include a first transverse member extending between opposing sides 31 A, 31 B of the base, adjacent the A-pillars 42A of the vehicle. A second transverse member 34B extends between opposing sides 31 A, 31 B of the base 31. Opposing ends of the second transverse member 32B are adjacent the B-pillars 42B of the vehicle 40. The base 31 tapers on either side of the cut-out 33 from a top of the second transverse member 32B towards a front 40A of the vehicle 40.

A third transverse member 34C extends between opposing sides 31 A, 31 B of the base 31. Opposing ends of the third transverse member 34C are adjacent the C-pillars 42C of the vehicle 40. A fourth transverse member 34D extends between opposing sides 31 A, 31 B of the base 31. Opposing ends of the fourth transverse member 32D are adjacent the D-pillars 42D of the vehicle 40.

In this embodiment, each transverse member 34B, 34C, 34D extends perpendicularly between opposing sides of the base 31.

The longitudinal members 32A, 32B extend between the second transverse member 34B, the third transverse member 34C and the fourth transverse member 34D on a top surface of the transverse members 34B, 34C, 34D. The longitudinal members 32A, 32B are elevated above the base 31 between the transverse members 34B, 34C, 34D. This allows the longitudinal members 32A, 32B to be used as a roof bars. The longitudinal members 32A, 32B are made from a lightweight material such as aluminium and are fixed to the transverse members 34B, 34C, 34D using a suitable adhesive, bolts, screws, rivets or any other suitable securing mechanism. Alternatively, the longitudinal members 32A, 32B are integrally formed with the transverse members 34B, 34C, 34D and the base 31. Referring to FIGS 8 and 9, accessories 60 may be integrated with the structure 30. The accessories 60 include high mounted lights 62 and a flashing light 64 however it should be appreciated that other accessories may be incorporated into the structure 30. Furthermore, the structure 30 may provide mounting points for other accessories such as roof bars and antennas. Although the accessories are shown as being mounted to the fourth transverse member 34D, is should be appreciated that the accessories may be integrated with any part of the structure 30.

FIG 12 shows a front perspective view of a roll over protection structure 70 mounted to a vehicle 80 according to a third embodiment of the present invention, and FIG 13 shows a translucent of the roll over protection structure 70 of FIG 12.

The roll over protection structure 70 of FIGs 12 and 13 is similar to the second embodiment shown in FIGs 7-11 and includes a base 71 , first and second longitudinal members 72A and 72B respectively and second, third and fourth transverse members 74B, 74C and 74D respectively. The transverse members 74 protrude above a generally flat top surface of the base 71. Note that the first and second longitudinal members 72A and 72B respectively have been removed from FIG 13 for clarity. Similarly, the roll over protection structure 70 is mounted to the vehicle

80, the vehicle including a front 80A, a rear 80B and structural pillars 82 in the form of A-pillars 82A, B-pillars 82B, C-pillars 82C and D-pillars 820. In this embodiment, the roll over protection structure 70 includes two additional transverse members in the form of a fifth transverse member 74E and a sixth transverse member 74F. The fifth and sixth transverse members 74E, 74F extend diagonally between opposing sides 71 A, 71 B of the base 71. The fifth transverse member 74E extends from a first side 71A of the base 71 , adjacent the A-pillar 82A of the vehicle 80, to an opposing second side 71 B of the base 71 , adjacent the D-pillar 82D on an opposite side of the vehicle 80. Although the fifth and sixth transverse members 74E, 74F are shown curved, it should be appreciated that the fifth and sixth transverse members 74E, 74F may extend directly between a respective A-pillar 82A and a respective D-pillar 82D.

In this embodiment, transverse members 74E, 74F extend diagonally between opposing sides of the base 71.

FIG 13 also shows optional reinforcing members 76B, 76C, 76D, 76E, 76F integrated into the base 71 and/or the transverse members 74. The reinforcing members 76 generally follow a same path as the transverse members 74 and the longitudinal members 72. FIG 13 does not show a first reinforcing member. However it should be appreciated that a first reinforcing member may be included between the first and second longitudinal members 72A and 72B, respectively adjacent the A-pillars 82A of the vehicle 80.

A second reinforcing member 76B extends between opposing sides 71 A, 71 B of the base 71. Opposing ends of the second reinforcing member 76B are adjacent the B-pillars 82B of the vehicle 80. A third reinforcing member 76C extends between opposing sides 71 A, 71 B of the base 71. Opposing ends of the third reinforcing member 34C are adjacent and correspond with the C-pillars 82C of the vehicle 80. A fourth reinforcing member 76D extends between opposing sides 71 A, 71 B of the base 71. Opposing ends of the fourth reinforcing member 76D are adjacent and correspond with the D-pillars 82D of the vehicle 80.

The fifth and sixth reinforcing members 76E and 76F, respectively, extend diagonally between opposing sides 71 A, 71 B of the base 71. The fifth reinforcing member 76E extends from the first side 71 A of the base 71 adjacent the A-pillar 82A of the vehicle 80 to the opposing second side 71 B of the base 71 adjacent the D-pillar 82D of the vehicle 80.

The sixth reinforcing member 76F extends from the second side 71 B of the base 71 adjacent the A-pillar 82A of the vehicle 80 to the opposing first side 71 A of the base 71 adjacent the D-pillar 82D of the vehicle 80. In addition, FIG 13 also shows reinforcing members 76G, 76H that extend longitudinally along each side of the roof of the vehicle 80. A seventh reinforcing member 76G extends from adjacent an A-pillar 82A of the vehicle 80 in a first side 71 A of the base 71 to adjacent a D-pillar 82D of the vehicle 80 in the first side 71 A of the base 71. Similarly, an eighth reinforcing member 76H extends from adjacent an A-pillar 82A of the vehicle 80 in a second side 71 B of the base 71 to adjacent a D-pillar 82D of the vehicle 80 in the second side 71 B of the base 71.

The reinforcing members 76 may be connected together, for example by welding, where one reinforcing member 76 intersects with another reinforcing member 76.

Although FIGS 12 and 13 show that the fifth and sixth reinforcing members 76E, 76F and the fifth and sixth transverse members 74E, 76F extend between a respective A-pillar and a respective D-pillar, it should be appreciated that the fifth and sixth transverse members 76E, 76F may extend between the first side 71A of the base 71 and the second side 71 B of the base 71 at a point adjacent any of the structural pillars 82 of the vehicle 80.

In use, the structure 10, 30, 70 is attached to a roof of a vehicle using an adhesive and bolted to the structural pillars 22, 42, 72 of the vehicle 20, 40, 80. However it should be appreciated that the structure 10, 30, 70 may be secured using any suitable securing hardware such as rivets and screws or secured using only an adhesive or secured by bolts alone.

The inventors believe that the structure 10, 30, 70 distributes impact forces across the structural pillars 22, 42, 72 of the vehicle 20, 40, 80 in the event of a roll over accident. For example a downward force applied to an A- pillar 22A, 42A, 82A may be distributed as follows. The longitudinal members 12, 32, 72 cantilever over the B-pillars 22B, 42B, 82B putting the B-pillars 22B, 42B, 82B in compression. The downward force is transmitted towards the rear 20B, 40B, 80B of the vehicle 20 putting the C-pillars 22C, 42C, 82C and the D-pillars 22D, 42D, 82D into tension. Thus a grid, created by the longitudinal members 12, 32, 72 the traverse members 14, 34, 74 and the pillar members 16 within the structure 10, 30, 70 will evenly distribute a downward force regardless of where the force is applied to the structure 10, 30, 70 or the vehicle's roof.

Additionally, the ROPS of the present invention adds significant stiffness and torsional strength to the vehicle as well as reinforcing the structural pillars such as the A and C pillars as required. Furthermore, according to an embodiment of the present invention, the ROPS of the present invention adds a diagonal rigidity to the vehicle by transmitting forces diagonally across the roof of the vehicle. The forces are distributed across all of the roof support pillars, and forces may be cantilevered over 'central' (B and C) pillars whilst 'end' (A and D) pillars may be either in compression or tension depending on the forces imparted.

Furthermore, in the event of a rollover, impact forces are distributed more evenly over the entire vehicle structure rather than concentrated around an impact zone. For example, in a rollover where the vehicle impacts the ground on a right hand side and forward of the B- pillar towards the front of the vehicle, the forces may be distributed as follows, referring to FIGs 12 and 13:

1. A right hand side 80D A-pillar 82A area will be in compression;

2. A right hand side 80D longitudinal member 72B and reinforcing member 76H will transfer the load towards the rear 80B of the vehicle 80 so that the right hand side 80D B- pillar 82B is in compression and the right hand side 80D, C and D pillars 82C, 82D are in tension; and

3. At the same time the diagonal transverse members 76E, 76F transmit the forces across the vehicle 80 putting the left hand side 80C, C and D pillars 82C, 82D in tension as well.

Additionally, the inventors believe that in the case of a hollow structure, a hollow structure filled with a structural foam and a hollow structure including reinforcing materials, the structure absorbs energy of the impact thus reduces damage to the vehicle.

Some advantages of the present invention include: a) As the structure is fitted externally to the vehicle, the structure does not encroach any of the internal space of the vehicle; b) An occupant of the vehicle is less likely to hit the structure in the event of a rollover accident; c) The structure is less likely to interfere with the SRS air bag systems of the vehicle; e) In the event of a rollover, the structure is less likely to trap an occupant; f) The structure enhances the standard safety features of the vehicle by maintaining the 'survival space' in a roll over accident; g) The structure is made from light weight materials thus the structure has a minimal effect on the vehicle's centre of gravity; h) The structure may also be used to mount light bars, antennas and other accessories; i) Accessories may be incorporated into the structure, for example high brake lamps; j) Carry bars, roof racks or task specific work platforms may also be incorporated into the design; k) The roof structure forward of the 'B' pillars (above the head of the driver and front seat passenger) is protected and reinforced. This critical area is not protected by many internal ROPS;

I) In the event of a rollover, impact forces are distributed more evenly over the entire vehicle structure rather than concentrated around an impact zone; m) Due to a combination of increased strength, improved rigidity and the ability to absorb crash energy the structure also helps to keep the windscreen and side glass intact in the event of rollover. Keeping the glass in the vehicle has a dual benefit of maintaining structural integrity of the vehicle and providing physical protection for occupants from debris. The windscreen and side glass also play a part in keeping the occupants limbs safely inside the vehicle.

It should be appreciated that various other changes and modifications made be made to the embodiment(s) described without departing from the spirit or scope of the invention.